Absorption chillers at a renowned textiles company

Established in 1984, a textiles manufacturer in Bangladesh has expanded dramatically over the past three decades and built a remarkable distinction as an exporting giant in the market. Thermax has supplied four units of steam fired vapour absorption chillers of 2700 TR, which deliver chilled water to meet the process cooling requirements of the textile plant.

Boiler Application In Jute Industry

THE CUSTOMER PROFILE

Champdany Industries Ltd (formerly Wellington Jute Mills) – a Kolkata based manufacturer and exporter of high quality jute products like yarn/twine, fine hessian cloth, jute bags, decorative jute fabrics and blended fabrics. Their manufacturing unit is at Rishra, about 25 kms from Kolkata. The plant’s steam requirements are met by a Thermax make 5 TPH boiler, fired on coal and jute caddy / briquettes.

THE CHALLENGE

The requirement called for a sustainable solution – taking into account the mix of fuels being burnt – not only on the combustion side but also on the pollution control side. The challenge was to come up with a system that would help the customer slash their energy costs, keeping emissions low at the same time.
Initially Electrostatic Precipitators (ESPs) were not in the reckoning, since they were not considered viable for boilers with capacities less than 10 TPH. But, with options like scrubbers and bag filters being ruled out on fuel mix and other technical grounds, the choice finally narrowed down to the ESP. The challenge was not only to achieve the desired results, but to do so in very limited space – a typical constraint especially in such old units
dating back to pre-independence times.

THE THERMAX -ENVIRO SOLUTION

Thermax came up with a new product to handle emissions from small boiler a ‘baby’ ESP. This uniquely designed ESP, developed in-house at Enviro, blends the best elements drawn from technology absorbed from two earlier collaborators. That Thermax has in fact delivered more than what was committed is visible from achieved 3 emission levels of less than 50 mg/Nm3 against the contractual 100 mg/Nm3.

TYPICAL ‘BABY’ ESP BOILER APPLICATIONS

Can be designed for different combustion systems based on:

  • Coal – Indian, Indonesian, Chinese, South African, Australian etc.
  • Lignite – Kutch, Neyveli etc
  • Agro Waste – Coconut/ Groundnut shells, Coffee waste, Tea leaves, Jute caddy, Chilli powder etc.
  • Wood
  • Oil
  • Multi-fuel
  • Waste heat recovery -from Sponge iron kilns, DG sets etc.

PROCESS PARAMETERS

Boiler: 5 TPH, Manual, Coal / Jute Caddy Fired

Fuel Coal Jute Caddy
Gas Volume (Am3 /hr) 14,076 14,520
Temperature (deg. C) 180 180
Inlet Dust Load (gm/Nm3) 15 20
Guaranteed Emission (mg/Nm3) 100 100
Actual Emission (mg/Nm3) 50 50

Handling fuel shift deftly for a polyester major

One of the largest producers of polyester fibres in India has a plant located at Patalganga in the state of Maharashtra. To deal with the rising prices of hydrocarbon fuels, the customer decided to switch to coal for operating its utilities. Catering to this requirement, the Boiler & Heater (B&H) division of Thermax commissioned two units of 15 MMkcal/hr coal-fired Dowtherm vapourisers for the customer. 

Dowtherm vapouriser is a preferred technology in manufacturing heat sensitive products such as fibres as it provides a more uniform heat source and precision temperature control. Thermax being pioneers in this application, customised the design for coal-fired vapourisers successfully. 

An atmospheric fluidised bed combustor burns Indonesian coal and is connected to a radiant and convective tube bank which generates the Dowtherm vapour. This solution will not only help bring down fuel costs for the customer but also recover their investment within a short time.

ZLD at Madhura Coats

Thermax recently installed a Zero Liquid Discharge (ZLD) plant with a recycling capacity of 3.6 million litres per day (MLD) at Madhura Coats, Ambasamudram, Tamil Nadu. This system consists of an effluent treatment plant (ETP), recycling plant & multiple effect evaporators (MEE). The wastewater generated from manufacturing activities such as thread dyeing and bleaching are treated in the ETP followed by the recycling plant. The membrane filtration based processes help recover good quality water from this treated wastewater. While the recovered water is used by manufacturing units, the rejected water is sent to the MEE. MEE reduces the volume of the waste to be handled, thereby disposing off the brine generated; leaving zero discharge at the end of the treatment cycle.

Chiller commissioned at a polyester manufacturer in Taiwan

The Cooling business supplied and commissioned a triple effect chiller at Taiwan’s Far Eastern New Century Corporation, one of the world’s top polyester suppliers. 

The 800 TR chiller air conditions the office and the shop floor. Additionally, it is used for jacket cooling in the roller machines. With global firms focusing on the twin objectives of using energy efficient products and protecting the environment, Thermax is building business partnership with reputed business houses across the world. It has also commissioned four double effect steam fired chillers of 1250 TR each to air-condition the R&D building of Samsung Electronics, Korea.

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